# US 11,898,345 B2 · Acoustic ceiling panel, method of manufacture and acoustic ceiling system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,898,345 B2 - Document ID: US11898345B2 - Status: Granted - Kind: B2 - Application number: 17/201,784 - Filed: 2021-03-15 - Published: 2021-09-16 - Granted: 2024-02-13 - Earliest claimed: 2020-03-13 - Assignees: CertainTeed Ceilings Corporation - Applicants: CertainTeed Ceilings Corporation - Inventors: Yanjia Zuo; Chris L. Heikkinen; John T. Madajewski; Phillip Evans; Chris W. Niemi; Jeremiah L. Shaffer; Isabelle Etchart Randlett; Robert Miller; Keith C. Hong; Zhengzhi Zhou - Web page: https://patentgrep.com/patent/US11898345B2 ## CPC - E04B 1/86: slab-shaped - E04B 9/0464: {having irregularities on the faces, e.g. holes, grooves} - E04B 9/001: {characterised by provisions for heat or sound insulation} - E04B 9/0435: {having connection means at the edges} - E04B 9/045: {being laminated} - E04B 9/225: {with the slabs, panels, sheets or the like hanging at a distance below the supporting construction} - E04B 9/241: {with the slabs, panels, sheets or the like positioned on the upperside of the horizontal flanges of the supporting construction} - E04B 9/28: with the slabs, {panels,} sheets or the like having grooves engaging with horizontal flanges of the supporting construction or accessory means connected thereto - E04B 2001/8461: {layered} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) ## Abstract The present disclosure relates generally to acoustic panels, for example, suitable for use in a ceiling to control sound. The present disclosure relates more particularly to an acoustic ceiling panel including an acoustic substrate formed of a porous material having an air flow resistivity of at least 300 kPa*s/m2. The acoustic substrate includes an upper face and a lower face with a pattern of perforations formed therein, where the pattern of perforations covers at least 6% of the area of the lower face. The acoustic ceiling panel also includes a backing layer disposed over the upper face of the acoustic substrate and a veil disposed over the lower face. ## Claims ### Claim 1 An acoustic ceiling panel comprising: an acoustic substrate formed of a porous material, the porous material comprising in the range of 60-95% on a dry weight basis of a fibrous material and in the range of 1-15% on a dry weight basis of a polymeric binder binding the fibrous material, the porous material having a density no more than 20 lb/ft3, the acoustic substrate having an air flow resistivity of at least 300 kPa*s/m2, the acoustic substrate including: an upper face, and a lower face with a pattern of perforations formed therein, the pattern of perforations covering at least 6% of the area of the lower face; a backing layer disposed over the upper face of the acoustic substrate; and a veil disposed over the lower face. ### Claim 2 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the air flow resistivity of the porous material is no more than 600 kPa*s/m2. ### Claim 3 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the pattern of perforations covers no more than 25% of the area of the lower face. ### Claim 4 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the acoustic substrate has a noise reduction coefficient (NRC) of at least at least 0.8. ### Claim 5 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the acoustic substrate has a ceiling attenuation class (CAC) of at least 25. ### Claim 6 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the average size of the perforations is at least 0.25 mm and is no more than 5 mm. ### Claim 7 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the average depth of the perforations is at least 40% of the thickness of the acoustic substrate, and is no more than 90% of the thickness of the acoustic substrate. ### Claim 8 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the average depth of the perforations is at least 0.1 inches and is no more than 2 inches. ### Claim 9 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the perforation pattern comprises a randomized pattern. ### Claim 10 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the perforation pattern comprises a geometric array. ### Claim 11 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the a fibrous material is selected from mineral wool, polymer fibers, cellulose fibers, and combinations thereof. ### Claim 12 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the porous material has a density of at least 6 lb/ft3. ### Claim 13 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the porous material has a porosity of at least 0.6. ### Claim 14 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the acoustic substrate has a thickness of at least ¼ inch and of no more than 2 inches. ### Claim 15 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the veil includes a fibrous material. ### Claim 16 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the acoustic ceiling panel has a length of at least 12 inches and no more than 20 feet. ### Claim 17 (depends on 1) The acoustic ceiling panel according to claim 1, wherein the acoustic ceiling panel has a width of at least 12 inches and of no more than 10 feet. ### Claim 18 (depends on 1) A method of making an acoustic ceiling panel according to claim 1, the method comprising: adding a plurality of components of the porous material of the acoustic substrate and water to a mixing tank; mixing the plurality of components and water in the mixing tank so as to form a slurry; dispensing the slurry onto a support surface; drying the slurry so as to form a slab of the porous material having a first face and a second face; forming perforations in the second face of the acoustic substrate; applying the backing layer over the first face of the acoustic substrate; and applying the veil over the second face of the acoustic substrate. ### Claim 19 (depends on 1) An acoustic ceiling system comprising: a ceiling support structure; and an acoustic ceiling panel according to claim 1 secured to the ceiling support structure. ### Claim 20 (depends on 19) The acoustic ceiling system according to claim 19, wherein the acoustic ceiling panel is one of an array of acoustic ceiling panels in the acoustic ceiling system. ### Claim 21 An acoustic ceiling panel comprising: an acoustic substrate formed of a porous material, the porous material comprising in the range of 60-95% on a dry weight basis of a fibrous material and in the range of 1-15% on a dry weight basis of a polymeric binder binding the fibrous material, the porous material having a density of at least 6 lb/ft3 and no more than 20 lb/ft3, the acoustic substrate having an air flow resistivity of at least 300 kPa*s/m2, the acoustic substrate including: an upper face, and a lower face with a pattern of perforations formed therein, the pattern of perforations covering at least 6% and no more than 25% of the area of the lower face, wherein the average depth of the perforations is at least 40% of the thickness of the acoustic substrate, and is no more than 90% of the thickness of the acoustic substrate, and the average size of the perforations is at least 0.25 mm and is no more than 5 mm; a backing layer disposed over the upper face of the acoustic substrate; and a veil disposed over the lower face.